US20160326880A1 - An additive manufacturing system utilizing an epitaxy process and method of operation - Google Patents
An additive manufacturing system utilizing an epitaxy process and method of operation Download PDFInfo
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- US20160326880A1 US20160326880A1 US15/109,351 US201515109351A US2016326880A1 US 20160326880 A1 US20160326880 A1 US 20160326880A1 US 201515109351 A US201515109351 A US 201515109351A US 2016326880 A1 US2016326880 A1 US 2016326880A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/10—Auxiliary heating means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/20—Cooling means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- B22F3/1055—
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0026—Auxiliary equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0093—Welding characterised by the properties of the materials to be welded
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/02—Control circuits therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
- B23K26/703—Cooling arrangements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
- C30B11/005—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method by irradiation or electric discharge
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
- C30B11/006—Controlling or regulating
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
- C30B11/14—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method characterised by the seed, e.g. its crystallographic orientation
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B13/00—Single-crystal growth by zone-melting; Refining by zone-melting
- C30B13/06—Single-crystal growth by zone-melting; Refining by zone-melting the molten zone not extending over the whole cross-section
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B13/00—Single-crystal growth by zone-melting; Refining by zone-melting
- C30B13/16—Heating of the molten zone
- C30B13/22—Heating of the molten zone by irradiation or electric discharge
- C30B13/24—Heating of the molten zone by irradiation or electric discharge using electromagnetic waves
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
- C30B29/10—Inorganic compounds or compositions
- C30B29/52—Alloys
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
- C30B29/60—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape characterised by shape
- C30B29/66—Crystals of complex geometrical shape, e.g. tubes, cylinders
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
- F01D5/3007—Fixing blades to rotors; Blade roots ; Blade spacers of axial insertion type
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2203/00—Controlling
- B22F2203/11—Controlling temperature, temperature profile
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2207/00—Aspects of the compositions, gradients
- B22F2207/11—Gradients other than composition gradients, e.g. size gradients
- B22F2207/15—Temperature gradients
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/45—Others, including non-metals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
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- B23K2203/08—
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/606—Directionally-solidified crystalline structures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/607—Monocrystallinity
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present disclosure relates to an additive manufacturing system and, more particularly, to an additive manufacturing system utilizing an epitaxy process and method of operation.
- ALM Additive Layer Manufacturing
- DMLS Direct Metal Laser Sintering
- SLM Selective Laser Melting
- LBM Laser Beam Melting
- EBM Electron Beam Melting
- DMLS Direct Metal Laser Sintering
- SLM Selective Laser Melting
- LBM Laser Beam Melting
- EBM Electron Beam Melting
- the EBM system utilizes an electron beam gun and the DMLS, SLM, and LBM systems utilize a laser as the energy source. Both system beam types are focused by a lens, then deflected by an electromagnetic scanner or rotating mirror so that the energy beam selectively impinges on a powder bed.
- the EBM system uses a beam of electrons accelerated by an electric potential difference and focused using electromagnetic lenses that selectively scans the powder bed.
- the DMLS, SLM and LBM utilize a focused laser beam scanned by a rotating mirror.
- the EBM technology offers higher power densities, and therefore faster scanning rates, over lasers, and is capable of processing superalloys. The powder is melted at the energy focus site on the build surface or substrate.
- the strategy of the scanning, power of the energy beam, residence time or speed, sequence of melting are directed by an embedded CAD system.
- the precursor powder is either gravitationally fed from cassettes or loaded by a piston so that it can be raked onto the build table.
- the excess powder is raked off and collected for re-application. Since the electron gun or laser is fixed, the build table can be lowered with each successive layer so that the workpiece is built upon the pre-solidified layer beneath.
- a method of additive manufacturing a workpiece includes providing a seed for propagating grain microstructure growth, covering the seed with a plurality of layers of a powder bed of a material capable of grain structure growth, melting at least in-part each successive layer of the plurality of layers utilizing an energy gun, controlling a solidification rate of each melted successive layer utilizing a cooling source located below the layer, forming a solidified slice of the workpiece and such that a grain structure of the seed propagates through the solidified slice, and proceeding to the next successive layer.
- the method includes controlling a thermal gradient across each successive layer.
- the seed and each slice includes a build surface and the step of melting each successive layer includes melting a meltback region of the build surface.
- the thermal gradient is controlled at least in-part by the cooling source.
- the thermal gradient is controlled at least in-part by a heating source disposed above the powder bed.
- the thermal gradient is controlled in-part by a heating source disposed above the powder bed.
- the solidification rate is also controlled utilizing a heating source located above the powder bed.
- the solidification rate is also controlled utilizing a heating source located above the powder bed.
- the method further includes heating the build surface of the seed or the slice to a predetermined temperature slightly below melting temperature with a heating source and before covering the seed or the slice with the next successive layer.
- the build surface is heated to about one hundred degrees Fahrenheit below melting temperature.
- the workpiece is a turbine component.
- the workpiece is a turbine blade.
- the seed is a cast manufactured fir tree of the turbine blade and the cooling source utilizes cooling channels in the fir tree.
- the cooling source has cooling channels in the seed for flowing a coolant.
- the method includes the further step of conditioning the build surface to a predetermined temperature that is below a melting point temperature of the material.
- the material is capable of directional grain structure.
- the material is capable of single crystal grain structure.
- the cooling source controls the solidification rate through thermal conduction through the seed.
- An additive manufacturing system for manufacturing a workpiece in successive slices includes a build table constructed and arranged to move vertically and support a powder bed and a seed for propagating microstructure grain growth, an energy gun for selectively melting a layer of the powder bed placed above the seed, a cooling source disposed below the layer and constructed and arranged to control at least a solidification rate of the melted layer, and a heating source disposed above the powder bed for at least controlling a temperature gradient of the melted layer.
- the system includes a controller, and a temperature sensor for measuring a build surface temperature of each successive slice and sending a feedback signal to the controller for control of the heating and cooling sources.
- FIG. 1 is a schematic view of an additive manufacturing system according to one non-limiting embodiment of the present disclosure
- FIG. 2 is a graph of a solidification rate verse a thermal gradient of an epitaxy process
- FIG. 3 is a graph of build height verse temperature for displaying directional solidification growth temperature gradients
- FIG. 4 is schematic view of a workpiece and seed manufactured by the additive manufacturing system.
- FIG. 5 is a schematic view of a second, non-limiting, embodiment of the workpiece and seed.
- FIG. 1 schematically illustrates an additive manufacturing system 20 having a build table 22 for holding a powder bed 24 , a particle spreader or wiper 26 for producing the powder bed 24 , an energy gun 28 for selectively melting regions of a layer of the powder bed, multiple heating sources 30 , and a cooling source 32 (with the sources controlling thermal gradients and solidification rates), a powder supply hopper 34 and a powder surplus hopper 36 .
- the additive manufacturing system 20 is constructed to build a workpiece 38 in a layer-by-layer fashion utilizing an epitaxy process for forming directional, microstructure grains or, for example, single crystal growth in an alloy.
- the workpiece 38 thus includes a seed or substrate 40 with a desired directional microstructure grain.
- a controller 42 may have an integral computer aided design system for modeling the workpiece 38 into a plurality of slices 44 additively built atop one-another generally in a vertical or z-coordinate direction (see arrow 46 ).
- Each solidified slice 44 corresponds to a layer 48 of the powder bed 24 prior to solidification.
- the layer 48 is placed on top of a build surface 50 of the previously solidified slice 44 , or during initial operation, the build surface of the seed 40 .
- the controller 42 generally operates the entire system through a series of electrical and/or digital signals 52 sent to the system 20 components. For instance, the controller 42 may send a signal 52 to a mechanical piston 54 of the supply hopper 34 to push a supply powder 56 upward for receipt by the spreader 26 .
- the spreader 26 may be a wiper, roller or other device that pushes (see arrow 60 ) or places the supply powder 56 over the build surface 50 of the workpiece 38 by a pre-determined thickness established by vertical, downward, movement (see arrow 62 ) of the build table 22 that supports the seed 40 . Any excess powder 64 may be pushed into the surplus hopper 36 by the spreader 26 .
- the controller 42 may send a signal to the energy gun 28 that energizes a laser or electron beam device 66 and controls a directional mechanism 68 of the gun 28 .
- the directional mechanism 68 may include a focusing lens that focuses a beam (see arrows 70 ) emitted from device 66 which, in-turn may be deflected by an electromagnetic scanner or rotating mirror of the mechanism 68 so that the energy beam 70 selectively and controllably impinges upon selected regions of the top layer 48 of the powder bed 24 .
- the beam 70 moves along the layer 48 melting region-by-region of the layer 48 at a controlled rate and power to, in-part, establish a predefined thermal gradient, generally melting each region into pools that then solidify at a controlled rate to promote the desired directional grain microstructure of the workpiece 38 .
- the additive manufacturing system 20 operates to achieve directional solidification of the workpiece through epitaxy, and avoid freckles whether created under equiaxed conditions or not. Therefore, at a pre-established and controlled solidification rate, the system 20 also operates to maintain and control a desirable thermal gradient toward the promotion of directional grains as found in the seed 40 and as the melted powder solidifies and forms a slice 44 of the workpiece 38 . More specifically, the controller 42 controls the elevated heating sources 30 that may be transiently operated (i.e. power output is adjustable) to establish the desired thermal gradient, and may be steady-state operated (i.e. power output is steady) to control the solidification rate. The controller 42 may control the heating and cooling sources 30 , 32 utilizing a temperature sensor 72 that provides a feedback signal 74 indicative of the build surface temperature.
- a temperature sensor 72 that provides a feedback signal 74 indicative of the build surface temperature.
- a temperature gradient TG 1 is the change in temperature over the height of the solidified workpiece layers that are already formed through the additive manufacturing process (i.e. distance from the seed 40 to the build surface 50 of the top slice 44 ).
- Temperature gradient TG 1 may be primarily dictated by the desire to maintain a build surface 50 predetermined temperature T 1 that is below a melting point temperature of the material, and may be slightly below melting temperature, and preferably about 100 degrees Fahrenheit below the melting temperature for a material that is a nickel based superalloy.
- the cooling source 32 may be the primary means to maintain temperature T 1 , but may also operate in conjunction with the heating source 30 .
- a temperature T 2 may be a melting temperature of the powder 56 .
- a temperature gradient TG 2 is the difference in temperature T 2 and temperature T 1 divided by the height Z of the working powder layer. Since temperature T 1 may be held constant throughout the additive manufacturing of the next successive top slice 44 , thermal gradient TG 1 will be constant for that slice and will be slightly lower for manufacturing of the next successive slice 44 . Moreover, thermal gradient TG 2 will decrease over time and as the melt pool of the powder layer solidifies. That is, temperature T 1 is held constant and temperature T 2 will decrease at a controlled rate primarily through transient operation of the heating source 30 . Referring further to FIG. 2 , this change in temperature of temperature T 2 is directly related to the solidification rate. Therefore, with a given solidification rate, the range of the decreasing thermal gradient TG 2 during solidification should generally be found in the ‘Directional Solidification with no Freckles’ region of FIG. 2 .
- the controller 42 operates to condition and maintain the build surface temperature T 1 slightly below melting and preferably about 100 degrees Fahrenheit below melting for nickel based superalloys, and will control the heating and cooling sources 30 , 32 accordingly. At this temperature, and for nickel based superalloys such as DSR 142 and Mar-M-247DS, with melting points ranging from about 2,400 to 2,600 degrees Fahrenheit, holding surface temperatures just below melting will relieve internal stresses created during manufacturing and assist in controlling the thermal gradient and establishing a meltback region into the build surface 50 . It is further understood and contemplated that the temperature sensor 72 may be an infrared sensor or any other type of sensor capable of non-contact measurement.
- the next successive layer 48 of powder 56 may then be spread over the surface.
- the temperature sensor 72 is used to measure the thermal gradient across the melted pool and generally in the z-coordinate direction 62 .
- Both the heating and cooling sources 30 , 32 are utilized to maintain a desired thermal gradient.
- the heating sources 30 may be transiently operated and of an oscillating type to further control local temperature gradients at the surface of the additive build.
- the thermal gradient is controlled in part through thermal conduction through the pre-solidified layers and the seed 40 via the cooling source 32 .
- the cooling source 32 may controllably flow coolant such as water through a series of channels 74 in the seed 40 to thermal conduction.
- the coolant source 32 may not be needed or may run at minimal flow. As the workpiece extends in the z-coordinate direction, through many slices, the cooling source 32 will ramp up as dictated by the controller 42 to induce further thermal conduction and maintain the desired thermal gradient.
- the heating and cooling sources 30 , 32 will operate similarly for controlling the solidification rate of the melted pools at a constant energy gun power, and to provide time for directional grain or single crystal growth as generally illustrated in FIG. 2 .
- the controller 42 may apply an inverse solution method to determine optimal build parameters including adjustment of the laser gun 28 power.
- the additive manufacturing system may include a method where fusing of powder is done by high-speed accumulation and then laser sintered (laser spray deposition); or, a method that utilizes materials that are capable of equiax grain properties, materials capable of directional solidified (DS) grain structure, or materials capable of single crystal (SX) grain structure.
- one non-limiting example of the workpiece 38 is a gas turbine engine blade having an airfoil 76 projecting outward from a platform 78 and a fir tree 80 projecting outward from the platform in an opposite direction.
- the fir tree 80 is attached to the seed 40 during fabrication.
- the seed 40 and thus the directional single crystal growth is generally in the z-coordinate direction (i.e. vertical).
- the seed 40 is removed after the additive manufacturing process is complete.
- any other turbine component, where single crystal growth is desirable may be the workpiece including complex and intricate turbine vanes.
- the seed 40 ′ is the fir tree of the blade or workpiece 38 ′.
- the typical cooling channels of the fir tree 80 ′ are used and applied as the cooling channels 74 ′ of the seed.
- the more simple structure of the fir tree 80 ′ may be cast as a single crystal structure and the remainder of the blade may be manufactured utilizing the additive manufacturing system.
- the platform 78 ′ of the blade may be cast along with the firtree 80 ′ at an optimum grain structure orientation.
- platforms of vanes may also be cast with optimum grain structure and then with the airfoil being additively manufactured onto the platform.
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Abstract
Description
- This application claims priority to U.S. Patent Appln. No. 61/929,359 filed Jan. 20, 2014.
- The present disclosure relates to an additive manufacturing system and, more particularly, to an additive manufacturing system utilizing an epitaxy process and method of operation.
- Traditional additive manufacturing systems include, for example, Additive Layer Manufacturing (ALM) devices, such as Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), Laser Beam Melting (LBM) and Electron Beam Melting (EBM) that provide for the fabrication of complex metal, alloy, polymer, ceramic and composite structures by the freeform construction of the workpiece, layer-by-layer. The principle behind additive manufacturing processes involves the selective melting of atomized precursor powder beds by a directed energy source, producing the lithographic build-up of the workpiece. The melting of the powder occurs in a small localized region of the energy beam, producing small volumes of melting, called melt pools, followed by rapid solidification, allowing for very precise control of the solidification process in the layer-by-layer fabrication of the workpiece. These devices are directed by three-dimensional geometry solid models developed in Computer Aided Design (CAD) software systems.
- The EBM system utilizes an electron beam gun and the DMLS, SLM, and LBM systems utilize a laser as the energy source. Both system beam types are focused by a lens, then deflected by an electromagnetic scanner or rotating mirror so that the energy beam selectively impinges on a powder bed. The EBM system uses a beam of electrons accelerated by an electric potential difference and focused using electromagnetic lenses that selectively scans the powder bed. The DMLS, SLM and LBM utilize a focused laser beam scanned by a rotating mirror. The EBM technology offers higher power densities, and therefore faster scanning rates, over lasers, and is capable of processing superalloys. The powder is melted at the energy focus site on the build surface or substrate. The strategy of the scanning, power of the energy beam, residence time or speed, sequence of melting are directed by an embedded CAD system. The precursor powder is either gravitationally fed from cassettes or loaded by a piston so that it can be raked onto the build table. The excess powder is raked off and collected for re-application. Since the electron gun or laser is fixed, the build table can be lowered with each successive layer so that the workpiece is built upon the pre-solidified layer beneath.
- Unfortunately, known additive manufacturing processes and systems do not apply epitaxy concepts and are not capable of manufacturing workpieces with a pre-specified, directionally solidified microstructure such as single crystal alloys.
- A method of additive manufacturing a workpiece according to one, non-limiting, embodiment of the present disclosure includes providing a seed for propagating grain microstructure growth, covering the seed with a plurality of layers of a powder bed of a material capable of grain structure growth, melting at least in-part each successive layer of the plurality of layers utilizing an energy gun, controlling a solidification rate of each melted successive layer utilizing a cooling source located below the layer, forming a solidified slice of the workpiece and such that a grain structure of the seed propagates through the solidified slice, and proceeding to the next successive layer.
- Additionally to the foregoing embodiment, the method includes controlling a thermal gradient across each successive layer.
- In the alternative or additionally thereto, in the foregoing embodiment the seed and each slice includes a build surface and the step of melting each successive layer includes melting a meltback region of the build surface.
- In the alternative or additionally thereto, in the foregoing embodiment the thermal gradient is controlled at least in-part by the cooling source.
- In the alternative or additionally thereto, in the foregoing embodiment the thermal gradient is controlled at least in-part by a heating source disposed above the powder bed.
- In the alternative or additionally thereto, in the foregoing embodiment the thermal gradient is controlled in-part by a heating source disposed above the powder bed.
- In the alternative or additionally thereto, in the foregoing embodiment the solidification rate is also controlled utilizing a heating source located above the powder bed.
- In the alternative or additionally thereto, in the foregoing embodiment the solidification rate is also controlled utilizing a heating source located above the powder bed.
- In the alternative or additionally thereto, in the foregoing embodiment the method further includes heating the build surface of the seed or the slice to a predetermined temperature slightly below melting temperature with a heating source and before covering the seed or the slice with the next successive layer.
- In the alternative or additionally thereto, in the foregoing embodiment the build surface is heated to about one hundred degrees Fahrenheit below melting temperature.
- In the alternative or additionally thereto, in the foregoing embodiment the workpiece is a turbine component.
- In the alternative or additionally thereto, in the foregoing embodiment the workpiece is a turbine blade.
- In the alternative or additionally thereto, in the foregoing embodiment the seed is a cast manufactured fir tree of the turbine blade and the cooling source utilizes cooling channels in the fir tree.
- In the alternative or additionally thereto, in the foregoing embodiment the cooling source has cooling channels in the seed for flowing a coolant.
- In the alternative or additionally thereto, in the foregoing embodiment, the method includes the further step of conditioning the build surface to a predetermined temperature that is below a melting point temperature of the material.
- In the alternative or additionally thereto, in the foregoing embodiment the material is capable of directional grain structure.
- In the alternative or additionally thereto, in the foregoing embodiment the material is capable of single crystal grain structure.
- In the alternative or additionally thereto, in the foregoing embodiment the cooling source controls the solidification rate through thermal conduction through the seed.
- An additive manufacturing system for manufacturing a workpiece in successive slices according to another, non-limiting embodiment includes a build table constructed and arranged to move vertically and support a powder bed and a seed for propagating microstructure grain growth, an energy gun for selectively melting a layer of the powder bed placed above the seed, a cooling source disposed below the layer and constructed and arranged to control at least a solidification rate of the melted layer, and a heating source disposed above the powder bed for at least controlling a temperature gradient of the melted layer.
- Additionally to the foregoing embodiment, the system includes a controller, and a temperature sensor for measuring a build surface temperature of each successive slice and sending a feedback signal to the controller for control of the heating and cooling sources.
- The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in-light of the following description and the accompanying drawings. It should be understood, however, the following description and figures are intended to be exemplary in nature and non-limiting.
- Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiments. The drawings that accompany the detailed description can be briefly described as follows:
-
FIG. 1 is a schematic view of an additive manufacturing system according to one non-limiting embodiment of the present disclosure; -
FIG. 2 is a graph of a solidification rate verse a thermal gradient of an epitaxy process; -
FIG. 3 is a graph of build height verse temperature for displaying directional solidification growth temperature gradients; -
FIG. 4 is schematic view of a workpiece and seed manufactured by the additive manufacturing system; and -
FIG. 5 is a schematic view of a second, non-limiting, embodiment of the workpiece and seed. -
FIG. 1 schematically illustrates anadditive manufacturing system 20 having a build table 22 for holding apowder bed 24, a particle spreader orwiper 26 for producing thepowder bed 24, anenergy gun 28 for selectively melting regions of a layer of the powder bed,multiple heating sources 30, and a cooling source 32 (with the sources controlling thermal gradients and solidification rates), apowder supply hopper 34 and apowder surplus hopper 36. Theadditive manufacturing system 20 is constructed to build aworkpiece 38 in a layer-by-layer fashion utilizing an epitaxy process for forming directional, microstructure grains or, for example, single crystal growth in an alloy. Theworkpiece 38 thus includes a seed orsubstrate 40 with a desired directional microstructure grain. - A
controller 42 may have an integral computer aided design system for modeling theworkpiece 38 into a plurality ofslices 44 additively built atop one-another generally in a vertical or z-coordinate direction (see arrow 46). Eachsolidified slice 44 corresponds to alayer 48 of thepowder bed 24 prior to solidification. Thelayer 48 is placed on top of abuild surface 50 of the previouslysolidified slice 44, or during initial operation, the build surface of theseed 40. Thecontroller 42 generally operates the entire system through a series of electrical and/ordigital signals 52 sent to thesystem 20 components. For instance, thecontroller 42 may send asignal 52 to amechanical piston 54 of thesupply hopper 34 to push asupply powder 56 upward for receipt by thespreader 26. Thespreader 26 may be a wiper, roller or other device that pushes (see arrow 60) or places thesupply powder 56 over thebuild surface 50 of theworkpiece 38 by a pre-determined thickness established by vertical, downward, movement (see arrow 62) of the build table 22 that supports theseed 40. Anyexcess powder 64 may be pushed into thesurplus hopper 36 by thespreader 26. - Once a substantially
level powder layer 48 is established over thebuild surface 50, thecontroller 42 may send a signal to theenergy gun 28 that energizes a laser orelectron beam device 66 and controls adirectional mechanism 68 of thegun 28. Thedirectional mechanism 68 may include a focusing lens that focuses a beam (see arrows 70) emitted fromdevice 66 which, in-turn may be deflected by an electromagnetic scanner or rotating mirror of themechanism 68 so that theenergy beam 70 selectively and controllably impinges upon selected regions of thetop layer 48 of thepowder bed 24. Thebeam 70 moves along thelayer 48 melting region-by-region of thelayer 48 at a controlled rate and power to, in-part, establish a predefined thermal gradient, generally melting each region into pools that then solidify at a controlled rate to promote the desired directional grain microstructure of theworkpiece 38. - Referring to
FIG. 2 , a graph of Solidification Rate verse Thermal Gradient is illustrated. Theadditive manufacturing system 20 operates to achieve directional solidification of the workpiece through epitaxy, and avoid freckles whether created under equiaxed conditions or not. Therefore, at a pre-established and controlled solidification rate, thesystem 20 also operates to maintain and control a desirable thermal gradient toward the promotion of directional grains as found in theseed 40 and as the melted powder solidifies and forms aslice 44 of theworkpiece 38. More specifically, thecontroller 42 controls theelevated heating sources 30 that may be transiently operated (i.e. power output is adjustable) to establish the desired thermal gradient, and may be steady-state operated (i.e. power output is steady) to control the solidification rate. Thecontroller 42 may control the heating andcooling sources temperature sensor 72 that provides afeedback signal 74 indicative of the build surface temperature. - Referring to
FIG. 3 , a directional solidification growth temperature gradient graph is illustrated. A temperature gradient TG1 is the change in temperature over the height of the solidified workpiece layers that are already formed through the additive manufacturing process (i.e. distance from theseed 40 to thebuild surface 50 of the top slice 44). Temperature gradient TG1 may be primarily dictated by the desire to maintain abuild surface 50 predetermined temperature T1 that is below a melting point temperature of the material, and may be slightly below melting temperature, and preferably about 100 degrees Fahrenheit below the melting temperature for a material that is a nickel based superalloy. With the production of increasing height (i.e. additional solidifiedslices 44 beneath the build surface 50), the coolingsource 32 may be the primary means to maintain temperature T1, but may also operate in conjunction with theheating source 30. - At a given state or point in time, a temperature T2 may be a melting temperature of the
powder 56. A temperature gradient TG2 is the difference in temperature T2 and temperature T1 divided by the height Z of the working powder layer. Since temperature T1 may be held constant throughout the additive manufacturing of the next successivetop slice 44, thermal gradient TG1 will be constant for that slice and will be slightly lower for manufacturing of the nextsuccessive slice 44. Moreover, thermal gradient TG2 will decrease over time and as the melt pool of the powder layer solidifies. That is, temperature T1 is held constant and temperature T2 will decrease at a controlled rate primarily through transient operation of theheating source 30. Referring further toFIG. 2 , this change in temperature of temperature T2 is directly related to the solidification rate. Therefore, with a given solidification rate, the range of the decreasing thermal gradient TG2 during solidification should generally be found in the ‘Directional Solidification with no Freckles’ region ofFIG. 2 . - The
controller 42 operates to condition and maintain the build surface temperature T1 slightly below melting and preferably about 100 degrees Fahrenheit below melting for nickel based superalloys, and will control the heating andcooling sources build surface 50. It is further understood and contemplated that thetemperature sensor 72 may be an infrared sensor or any other type of sensor capable of non-contact measurement. - With the
build surface 50 at the pre-specified temperature, the nextsuccessive layer 48 ofpowder 56 may then be spread over the surface. When melted by thebeam 70, thetemperature sensor 72 is used to measure the thermal gradient across the melted pool and generally in the z-coordinatedirection 62. Both the heating andcooling sources heating sources 30 may be transiently operated and of an oscillating type to further control local temperature gradients at the surface of the additive build. Further, the thermal gradient is controlled in part through thermal conduction through the pre-solidified layers and theseed 40 via thecooling source 32. The coolingsource 32 may controllably flow coolant such as water through a series ofchannels 74 in theseed 40 to thermal conduction. During fabrication of the firstfew slices 44 of theworkpiece 38, thecoolant source 32 may not be needed or may run at minimal flow. As the workpiece extends in the z-coordinate direction, through many slices, the coolingsource 32 will ramp up as dictated by thecontroller 42 to induce further thermal conduction and maintain the desired thermal gradient. - The heating and
cooling sources FIG. 2 . Thecontroller 42 may apply an inverse solution method to determine optimal build parameters including adjustment of thelaser gun 28 power. It is further understood and contemplated that the additive manufacturing system may include a method where fusing of powder is done by high-speed accumulation and then laser sintered (laser spray deposition); or, a method that utilizes materials that are capable of equiax grain properties, materials capable of directional solidified (DS) grain structure, or materials capable of single crystal (SX) grain structure. - Referring to
FIG. 4 , one non-limiting example of theworkpiece 38 is a gas turbine engine blade having anairfoil 76 projecting outward from aplatform 78 and afir tree 80 projecting outward from the platform in an opposite direction. In this example, thefir tree 80 is attached to theseed 40 during fabrication. Theseed 40 and thus the directional single crystal growth is generally in the z-coordinate direction (i.e. vertical). Theseed 40 is removed after the additive manufacturing process is complete. It is further understood and contemplated that any other turbine component, where single crystal growth is desirable, may be the workpiece including complex and intricate turbine vanes. - Referring to
FIG. 5 , a second non-limiting example of the present disclosure is illustrated wherein like elements have like identifying numerals except with the addition of a prim symbol. In this example, theseed 40′ is the fir tree of the blade orworkpiece 38′. The typical cooling channels of thefir tree 80′ are used and applied as the coolingchannels 74′ of the seed. Moreover, and to reduce manufacturing costs, the more simple structure of thefir tree 80′ may be cast as a single crystal structure and the remainder of the blade may be manufactured utilizing the additive manufacturing system. It is further contemplated and understood that theplatform 78′ of the blade may be cast along with thefirtree 80′ at an optimum grain structure orientation. Furthermore, platforms of vanes may also be cast with optimum grain structure and then with the airfoil being additively manufactured onto the platform. - It is understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude and should not be considered otherwise limiting. It is also understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will also benefit. Although particular step sequences may be shown, described, and claimed, it is understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present disclosure.
- The foregoing description is exemplary rather than defined by the limitations described. Various non-limiting embodiments are disclosed; however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For this reason, the appended claims should be studied to determine true scope and content.
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US10012088B2 (en) | 2018-07-03 |
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EP3096905A4 (en) | 2017-02-08 |
WO2015109102A1 (en) | 2015-07-23 |
EP3096905A1 (en) | 2016-11-30 |
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